Linear Motor Track System With Automatic Gravity Detection

ABSTRACT

A mover is configured to be electromagnetically propelled along a track in a linear motor track system with a force that is calculated to include compensation for gravity. A multi-axis accelerometer arranged in each segment of the track can detect an orientation or angle of the track segment for determining gravity with respect to the particular section. As a result, if the track is at an incline, such as a ramp, a desired force for moving a mover along the track can be compensated to include gravity due to the incline for achieving a desired motion result. In addition, the detected orientation of the track can be compared to an expected orientation stored by a control program to avoid a loss of performance due to physical changes in the track not matching an expected/programmed configuration of the track.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/186,960. filed on Nov. 12, 2018, the contents of which are all herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates to motion control systems and, morespecifically, to motion control systems including a track segment forlinear motor drive systems supporting movers on tracks in which powerfor electromagnetically propelling a mover is controlled to include adesired force for moving the mover along a track segment when arrangedin a reference orientation and a compensated force for compensating foran orientation of the track segment differing from the referenceorientation.

BACKGROUND OF THE INVENTION

Motion control systems utilizing movers and linear motors can be used ina wide variety of processes (e.g. packaging, manufacturing, andmachining) and can provide an advantage over conventional conveyor beltsystems with enhanced flexibility, extremely high speed movement, andmechanical simplicity. The motion control system includes a set ofindependently controlled “movers” each supported on a track for motionalong the track. The track is made up of a number of track segments orsections that, in turn, hold individually controllable electric coils.Successive activation of the coils establishes a moving electromagneticfield that interacts with the movers and causes the mover to travelalong the track. Sensors, such as Hall Effect sensors orMagnetoresistance sensors, may be spaced at fixed positions along thetrack and/or on the movers for detecting opposing magnets to provideinformation about the position and speed of the movers.

Each of the movers may be independently moved and positioned along thetrack in response to the moving electromagnetic field generated by thecoils. In a typical system, the track forms a closed path over whicheach mover repeatedly travels. At certain positions along the trackother actuators may interact with each mover. For example, the mover maybe stopped at a loading station at which a first actuator places aproduct on the mover. The mover may then be moved along a processsegment of the track where various other actuators may fill, machine,position, or otherwise interact with the product on the mover. The movermay be programmed to stop at various locations or to move at acontrolled speed past each of the other actuators. After the variousprocesses are performed, the mover may pass or stop at an unloadingstation at which the product is removed from the mover. The mover thencompletes a cycle along the closed path by returning to the loadingstation to receive another unit of the product.

Motion of the movers along the track can be susceptible to disturbances,such as gravity. Such disturbances can inhibit the movers from achievingan expected motion that may be desired. It is therefore desirable toprovide an improved linear motor drive system that may overcome one ormore of the aforementioned drawbacks.

SUMMARY OF THE INVENTION

A mover is configured to be electromagnetically propelled along a trackin a linear motor track system with a force that is calculated toinclude compensation for gravity. A multi-axis accelerometer arranged ineach segment of the track can detect an orientation or angle of thetrack segment for determining gravity with respect to the particularsection. As a result, if the track is at an incline, such as a ramp, adesired force for moving a mover along the track can be compensated toinclude gravity due to the incline for achieving a desired motionresult. In addition, the detected orientation of the track can becompared to an expected orientation stored by a control program to avoida loss of performance due to physical changes in the track not matchingan expected/programmed configuration of the track.

In one aspect, linear motor track systems can be oriented in any angle.Servo control loops can be improved by compensating for a gravity vectoracting on movers in the system as a known disturbance. The servocontroller can detect the gravity vector at each section of the track.Undesired behavior can be avoided if a certain orientation which wasassumed at program time is changed during commissioning or run time. Asensor can be used for automatic detection of the gravity vector at eachsection. For example, a MEMS accelerometer sensor can be used. Automatic“keying” of a programmed orientation, which may be configured in aconfiguration software, such as Logix as available from RockwellAutomation, Inc., can be done with respect to actual orientation of thesection. Such keying could be done in discrete angle steps (such as 0°,45°, 90°, and so forth). As a result, a mover control system canautomatically compensate for changes to the gravity vector experiencedby the mover. In addition, programmed orientation of the system can bekeyed against a physical (detected) mounting orientation. Automaticdetection can allow any-angle mounting for sections of track to becompensated. Also, keying actual orientation against user input can beused to ensure the programmer's intent of orientation is correctlyimplemented by the system commissioner. For example, a programmer mighthave assumed an upright track in which all movers are brought to abottom section in a “Track-Stop” routine. However, if this orientationis changed during commissioning, it may result in undesired effect, suchas a free-fall of movers during execution of the Track Stop routine. Akeying-mismatch error according to the present invention could warn ofthis condition.

In one aspect, to determine an appropriate gravity compensation force toapply with respect to a mover, a measured gravity vector can be appliedwith an instantaneous direction of travel of the mover. Informationdefining the direction of travel can be stored in each section, at eachposition along the section, as a 3 dimensional vector on which the movertravels. A section can have arbitrary geometry, and a path of a mover onany given section could follow any 3 dimensional path (and not simply alinear or curved path).

Specifically then, one aspect of the present invention can provide alinear motor drive system, including: a track segment defining a pathalong which a mover travels, the track segment receiving power from apower supply for electromagnetically propelling a mover, the tracksegment including: multiple drive coils spaced along the track segment;and a sensor configured to detect an acceleration with respect to thetrack segment; and a controller in communication with the track segment,the controller executing a program stored in a non-transient medium tocontrol power to the drive coils for electromagnetically propelling amover with a total force to move the mover along the track segment,wherein the total force comprises: a desired force for moving the moveralong a track segment when arranged in a reference orientation; and acompensated force comprising the acceleration for compensating for anorientation of the track segment differing from the referenceorientation.

Another aspect of the present invention can provide a method forpropelling a mover, including: receiving power from a power supply forelectromagnetically propelling a mover along a track segment defining apath on which the mover travels, the track segment including: multipledrive coils spaced along the track segment; and a sensor detecting anacceleration with respect to the track segment; and controlling thepower to the drive coils for electromagnetically propelling the moverwith a total force to move the mover along the track segment, whereinthe total force comprises: a desired force for moving the mover along atrack segment when arranged in a reference orientation; and acompensated force comprising the acceleration for compensating for anorientation of the track segment differing from the referenceorientation.

These and other advantages and features of the invention will becomeapparent to those skilled in the art from the detailed description andthe accompanying drawings. It should be understood, however, that thedetailed description and accompanying drawings, while indicatingpreferred embodiments of the present invention, are given by way ofillustration and not of limitation. Many changes and modifications maybe made within the scope of the present invention without departing fromthe spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of the subject matter disclosed herein areillustrated in the accompanying drawings in which like referencenumerals represent like parts throughout, and in which:

FIG. 1 is an isometric view of an exemplary transport systemincorporating multiple movers travelling along a closed curvilineartrack according to one embodiment of the present invention;

FIG. 2 is a partial side elevation view of one segment of the transportsystem of FIG. 1 illustrating activation coils distributed along onesurface of the track segment;

FIG. 3 is a partial sectional view of the transport system of FIG. 1;

FIG. 4 is a block diagram representation of an exemplary power andcontrol system for the transport system of FIG. 1;

FIG. 5 is a block diagram representation of an exemplary servo controlsystem for propelling a mover with force in the transport system of FIG.1;

FIG. 6 is a diagram illustrating determination of gravity with respectto a section of track for compensating the force in the block diagram ofFIG. 5; and

FIG. 7 is a diagram illustrating determination of gravity with respectto a mover in accordance with aspect of the invention.

In describing the various embodiments of the invention which areillustrated in the drawings, specific terminology will be resorted tofor the sake of clarity. However, it is not intended that the inventionbe limited to the specific terms so selected and it is understood thateach specific term includes all technical equivalents which operate in asimilar manner to accomplish a similar purpose. For example, the word“connected,” “attached,” or terms similar thereto are often used. Theyare not limited to direct connection but include connection throughother elements where such connection is recognized as being equivalentby those skilled in the art.

DETAILED DESCRIPTION

The various features and advantageous details of the subject matterdisclosed herein are explained more fully with reference to thenon-limiting embodiments described in detail in the followingdescription.

Turning initially to FIG. 1, an exemplary transport system for movingarticles or products includes a track 10 made up of multiple segments 12or sections, such as segments 12 a, 12 b, 12 c and so forth. Accordingto the illustrated embodiment, the segments 12 define a generally closedloop supporting a set of movers 100 movable along the track 10. Thetrack 10 can be oriented in any plane with support from a mounted base15 extending from the track 10. According to the illustrated embodiment,the base 15 includes a pair of generally planar support plates 17,located on opposite sides of the track 10, with mounting feet 19 on eachsupport plate 17 to secure the track 10 to a surface, such as a floor,wall, ceiling, ramp or the like. The illustrated track 10 includes fourstraight segments 12, with two straight segments 12 located along eachside of the track and spaced apart from the other pair, such as straightsegments 12 a and 12 b on a first side of the track 10, oppositestraight segments 12 e and 12 f on a second side of the track 10. Thetrack 10 also includes four curved segments 12 where a pair of curvedsegments 12 is located at each end of the track 10 to connect the pairsof straight segments 12, such as curved segments 12 c and 12 d on afirst end of the track, opposite curved segments 12 g and 12 h on asecond end of the track 10. As illustrated, the four straight segments12 and the four curved segments 12 form a generally oval track anddefine a closed surface over which each of the movers 100 may travel. Itis understood that track segments of various sizes, lengths, and shapesmay be connected together to form a track 10 without deviating from thescope of the invention.

For convenience, a horizontal orientation of the track 10 is shown inFIG. 1. Terms such as upper, lower, inner, and outer will be used withrespect to the illustrated track orientation. These terms are relationalwith respect to the illustrated track and are not intended to belimiting. It is understood that the track may be installed in differentorientations, such as sloped or vertical, and include different shapedsegments including, but not limited to, straight segments, inward bends,outward bends, up slopes, down slopes and various combinations thereof.Further, each track segment 12 is shown in a generally horizontalorientation. The track segments 12 may also be oriented in a generallyvertical orientation and the width of the track 10 may be greater ineither the horizontal or vertical direction according to applicationrequirements. The movers 100 will travel along the track and takevarious orientations according to the configuration of the track 10 andthe relationships discussed herein may vary accordingly.

Each track segment 12 includes a number of independently attached rails20 on which each mover 100 runs. According to the illustratedembodiment, rails 20 extend generally along the outer periphery of thetrack 10. A first rail 20 extends along an upper surface 11 of eachsegment and a second rail 20 extends along a lower surface 13 of eachsegment. With reference also to FIGS. 2 and 3, the illustratedembodiment of each rail 20 includes a base 22 and a track portion 24.The base 22 is secured to the upper surface 11 or lower surface 13 ofeach segment 12 and the track portion 24 is mounted to the base 22. Itis contemplated that each rail 20 may be a singular, molded or extrudedmember or formed from multiple members. It is also contemplated that thecross section of the rails 20 may be circular, square, rectangular, orany other desired cross-sectional shape without deviating from the scopeof the invention. The rails 20 generally conform to the curvature of thetrack 10 thus extending in a straight path along the straight tracksegments 12 and in a curved path along the curved track segments 12. Therails 20 may be thin with respect to the width of the track 10 and spanonly a partial width of the surface of the track 10 on which it isattached. Each mover 100 includes complementary rollers 110 to engagethe track portion 24 of the rail 20 for movement along the track 10.

One or more movers 100 are mounted to and movable along the rails 20 onthe track 10. Each mover 100 includes a side member 102, a top member104, and a bottom member 106. The side member 102 extends for a heightat least spanning a distance between the rail 20 on the top surface 11of the track 10 and the rail 20 on the bottom surface 13 of the track 10and is oriented generally parallel to a side surface 21 when mounted tothe track 10. The top member 104 extends generally orthogonal to theside member 102 at a top end of the side member 102 and extends acrossthe rail 20 on the top surface 11 of the track 10. The top member 104includes a first segment 103, extending orthogonally from the sidemember 102 for the width of the rail 20, which is generally the samewidth as the side member 102. A set of rollers 110 are mounted on thelower side of the first segment 103 and are configured to engage thetrack portion 24 of the rail 20 mounted to the upper surface 11 of thetrack segment. According to the illustrated embodiment two pairs ofrollers 110 are mounted to the lower side of the first segment 103 witha first pair located along a first edge of the track portion 24 of therail and a second pair located along a second edge of the track portion24 of the rail 20. The first and second edges and, therefore, the firstand second pairs of rollers 110 are on opposite sides of the rail 20 andpositively retain the mover 100 to the rail 20. The bottom member 106extends generally orthogonal to the side member 102 at a bottom end ofthe side member 102 and extends for a distance sufficient to receive athird pair of rollers 110 along the bottom of the mover 100. The thirdpair of rollers 110 engage an outer edge of the track portion 24 of therail 20 mounted to the lower surface 13 of the track segment. Thus, themover 100 rides along the rails 20 on the rollers 110 mounted to boththe top member 104 and the bottom member 106 of each mover 100. The topmember 104 also includes a second segment 120 which protrudes from thefirst segment 103 an additional distance beyond the rail 20 and isconfigured to hold a position magnet 130. According to the illustratedembodiment, the second segment 120 of the top member 104 includes afirst portion 122 extending generally parallel to the rail 20 andtapering to a smaller width than the first segment 103 of the top member104. The second segment 120 also includes a second portion 124 extendingdownward from and generally orthogonal to the first portion 122. Thesecond portion 124 extends downward a distance less than the distance tothe upper surface 11 of the track segment but of sufficient distance tohave the position magnet 130 mounted thereto. According to theillustrated embodiment, a position magnet 130 is mounted within a recess126 on the second portion 124 and is configured to align with a tracksensor 150 mounted to the top surface 11 of the track segment.

A linear motor drive system is incorporated in part on each mover 100and in part within each track segment 12 to control motion of each mover100 along the segment. On each mover 100, the linear drive systemincludes multiple drive magnets 140 mounted to the side member 102. Thedrive magnets 140 can be arranged in a block along an inner surface ofthe side member 102 with separate magnet segments alternately having anorth pole, N, and south pole, S, pole facing the track segment. Thedrive magnets 140 are typically permanent magnets, and two adjacentmagnet segments including a north pole and a south pole may beconsidered a pole-pair. The drive magnets 140 are mounted on the innersurface of the side member 102 and when mounted to the track 10 arespaced apart from a series of coils 50 extending along the track 10. Asshown in FIG. 3, an air gap 141 is provided between each set of drivemagnets 140 and the coils 50 along the track 10. On the track 10, thelinear drive system includes a series of parallel coils 50 spaced alongeach track segment 12 as shown in FIG. 2. According to the illustratedembodiment, each coil 50 is placed in a channel 23 extendinglongitudinally along one surface of the track segment 12. Theelectromagnetic field generated by each coil 50 spans the air gap andinteracts with the drive magnets 140 mounted to the mover 100 to controloperation of the mover 100.

Turning next to FIG. 4, an exemplary power and control system for thetrack 10 and linear drive system is illustrated. A segment controller200 is mounted within each segment 12, with first and second segmentcontrollers 200 a and 200 b for first and second segments 12 a and 12 b,respectively, shown by way of example. Each segment controller 200receives command signals from a system controller 30 and generatesswitching signals for motor phases or power segments controllingactivation of corresponding coils 50 in the segments 12 from powerprovided by a power supply 180. Activation of the coils 50 arecontrolled by switches in the segments 12 to drive and position movers100 along the track.

The illustrated motion control system includes a system controller 30having a processor 32 and a memory device 34. It is contemplated thatthe processor 32 and memory device 34 may each be a single electronicdevice or formed from multiple devices. The processor 32 may be amicroprocessor. Optionally, the processor 32 and/or the memory device 34may be integrated on a field programmable array (FPGA) or an applicationspecific integrated circuit (ASIC). The memory device 34 may includevolatile memory, non-volatile memory, or a combination thereof. Thesystem controller 30 could be a Programmable Logic Controller (PLC). Auser interface 36 is provided for an operator to configure the systemcontroller 30 and to load or configure desired motion profiles for themovers 100 on the system controller 30. It is contemplated that thesystem controller 30 and user interface 36 may be a single device, suchas a laptop, notebook, tablet or other mobile computing device.Optionally, the user interface 36 may include one or more separatedevices such as a keyboard, mouse, display, touchscreen, interface port,removable storage medium or medium reader and the like for receivinginformation from and displaying information to a user. Optionally, thesystem controller 30 and user interface 36 may be integrated into anindustrial computer mounted within a control cabinet and configured towithstand harsh operating environments. It is contemplated that stillother combinations of computing devices and peripherals as would beunderstood in the art may be utilized or incorporated into the systemcontroller 30 and user interface 36 without deviating from the scope ofthe invention.

One or more programs may be stored in the memory device 34 for executionby the processor 32. The system controller 30 receives one or moremotion profiles for the movers 100 to follow along the track 10. Aprogram executing on the processor 32 is in communication with a segmentcontroller 200 on each track segment 12 via a control network 201, suchas an EtherNet/IP network. The system controller 30 may transfer adesired motion profile to each segment controller 200 or, optionally,the system controller 30 may perform some initial processing based onthe motion profile to transmit a segment of the motion profile to eachsegment controller 200 according to the portion of the motion profile tobe executed along that segment. Optionally, the system controller 30 mayperform still further processing on the motion profile and generate adesired switching sequence for each segment 12 that may be transmittedto the segment controller 200.

A network communication interface 202 in each segment controller 200receives the communications from the system controller 30 and passes thecommunication to a processor 204 executing in the segment controller200. The processor may be a microprocessor. Optionally, the processor204 and/or a memory device 206 within the segment controller 200 may beintegrated on a field programmable array (FPGA) or an applicationspecific integrated circuit (ASIC). It is contemplated that theprocessor 204 and memory device 206 may each be a single electronicdevice or formed from multiple devices. The memory device 206 mayinclude volatile memory, non-volatile memory, or a combination thereof.The segment controller 200 receives the motion profile, or portionthereof, or the switching sequence transmitted from the systemcontroller 30 and utilizes the motion profile or switching sequence tocontrol movers 100 present along the track segment 12 controlled by thatsystem controller 30.

Referring again to FIG. 1, each track segment 12 can include a PrintedCircuit Board (PCB) 210, such as a first PCB 210 a at segment 12 a, asecond PCB 210 b at segment 12 b, and so forth, with multipleelectronics mounted thereon. Such electronics can include a segmentcontroller 200 and a sensor 212 configured to detect an accelerationwith respect to the track segment 12. In particular, the sensor 212could be a triple axis micro electro mechanical system (MEMS) digitalaccelerometer configured to detect x, y and z components ofacceleration. A controller in communication with the track segment, suchas the segment controller 200 or the system controller 30, can execute aprogram to control power from the power supply 180 to the coils 50 forelectromagnetically propelling movers 100 along the track. Such powercan be controlled to produce a total force (“F_(TOTAL)”) to move themover 100 along the track segment 12. The total force can include: adesired force (“F_(D)”) for moving the mover 100 along a track segment12 when the track segment 12 is arranged in a reference orientation,such as substantially horizontal or flat with an angle of 0° withrespect to the ground; and a compensated force (“F_(COMP)”) comprisingthe acceleration detected by the sensor 212 for compensating for anorientation of the track segment differing from the referenceorientation, such as a non-zero angle with respect to the ground. Thecompensated force will typically comprise acceleration due to gravity onthe track segment 12 being a static system. The acceleration willtypically be a vector sum of the aforementioned x, y and z components.

With additional reference to FIG. 5, to move a mover 100 along a tracksegment, a controller, which could be the segment controller 200 orsystem controller 30, depending on where the motion profile isdetermined, can execute a servo control loop to determine the desiredmotion. In particular, to implement the motion profile with varyingposition and speed, the controller can continuously calculate a torquecommand and a torque trim or offset, compared to an accelerationreference, in a force command block 220 to provide a force command formoving the mover 100. Then, the force command can be compensated in aforce compensation block 222 to provide an adjusted or total forcecommand which accounts for forces due to acceleration (by gravity)detected by the track segment 12. In the force compensation block 222,the controller can read the sensor 212 to detect an acceleration vectorat the track segment 12, which the controller can use, along with storedsection geometry data indicative of the section geometry of the tracksegment, to compensate the force. Then, the force command can betranslated into in a current command at a current command block 224. Thecurrent command can be used to control power, sourced from the powersupply 180, to the coils 50 for electromagnetically propelling the mover100 along the track segment 12 as desired.

By way of example, with additional reference to FIG. 6, a mover 100′ canbe controlled to move along a track segment 12′ that is oriented at anon-zero angle with respect to the ground, such as up a 45° ramp. Asensor 212′ can be configured with respect to the track segment 12′ todetect x, y and z vector components of acceleration with respect to thetrack segment 12′. In FIG. 6, only x and y components “a_(x)” and“a_(y),” respectively, are illustrated in two dimensions for ease ofillustration, though a z component can be present. For the static tracksegment 12′, a vector sum of the x, y and z components will correspondto gravity “g.”

A controller executing a motion profile for the mover 100′ can determinea desired force F_(D) for moving the mover 100′ along a track segment 12when the track segment 12 is arranged in a reference orientation, suchas substantially horizontal or flat with an angle of 0° with respect tothe ground. The desired force can comprise a mass of the mover 100′multiplied by a desired acceleration “a_(D)” for the mover 100′ in thereference orientation. In addition, the sensor 212′ can be used todetect acceleration at the track segment 12′ to be compensated. In thisexample, the acceleration component in the x direction corresponding tothe direction of motion of the mover 100′ can be compensated while theacceleration component in the y direction corresponding to a directionnormal to the track remains static (as does the acceleration componentin the z direction which is not shown). Accordingly, the controllerexecuting the motion profile for the mover 100′ can determine acompensated force F_(COMP) comprising the acceleration detected by thesensor 212′ to be compensated, corresponding to the direction of motionof the mover 100′, which is a non-zero angle with respect to the ground,multiplied by the mass of the mover 100′. The controller can thencontrol power from the power supply 180 to the coils 50 for producing atotal force F_(TOTAL) on the mover 100′, which is the vector sum of thedesired force F_(D) and the compensated force F_(COMP), to move themover 100′ along the track segment 12′.

When the mover 100′ transitions to a next track segment 12″, acontroller, which could be the segment controller 200 for the next tracksegment 12″ or the system controller 30, can then reference the sensor212″ of the next track segment 12″ for updating the total forceF_(TOTAL), including the desired force F_(D) and the compensated forceF_(COMP).

In one aspect, the controller, such as the segment controller 200 or thesystem controller 30, can execute to determine the orientation of thetrack segment 12 from the sensor 212 (detecting the acceleration vectorsum from the sensor) to produce a result for the track segment. Theresult could comprise an angle of the track from a vector sum from thesensor 212 as described above with respect to FIGS. 5 and 6. Forexample, the result could indicate a track segment 12 oriented at one ormore discrete angle steps, such as an angle of 0°, 45°, 90°, or thelike, with respect to any detected axis, as detected during systemcommissioning or run time. The result can then be compared to aparameter for the corresponding track segment 12 stored in a datastructure. The parameter could also indicate, for example, the tracksegment 12 oriented at one or more discrete angle steps, such as anangle of 0°, 45°, 90°, or the like, with respect to any detected axis,as configured at the time of programming. Comparing the one or moreresults to the one or more parameters can provide automatic “keying” ofa sensed orientation versus a programmed orientation for any curvatureof the track. This can allow verification of the system for addedreliability.

For example, a programmer might have assumed an upright track in whichall movers 100 are brought to a bottom track segment 12 in a“Track-Stop” routine. However, if this orientation is changed duringcommissioning, it may result in undesired effect, such as a free-fall ofmovers 100 during execution of the Track Stop routine. Theaforementioned automatic keying can detect a keying-mismatch errorbefore such a routine is executed to avoid the undesired effect.

In addition, in one aspect, the controller, such as the segmentcontroller 200 or the system controller 30, can execute to determine theorientation of the track segment 12 from the sensor 212 (detecting theacceleration vector sum from the sensor) at first and second times toproduce first and second results, respectively. The first and secondtimes can then be compared to one another to determine an error. Forexample, if an angle of 45° is detected at the first time as a firstresult, then an angle of 46° is detected at the second time as a secondresult, a comparison between the first and second results can reveal anerror if 1°. This non-zero error can indicate, for example, an amount ofvibration of the track segment 12. Moreover, when the first and secondtimes each occur when a single mover 100 is moving along the tracksegment 12, the error can indicate a vibration caused by the mover 100,such as faulty bearings or rollers 110.

Referring now to FIG. 7, in another aspect of the invention, todetermine an appropriate gravity compensation force to apply withrespect to a mover 100″, a measured gravity vector 188 can be appliedwith an instantaneous direction of travel 190 of the mover 100″.Information defining the direction of travel 190 can be stored in eachsection 12, at each position along the section 12, as a 3 dimensionalvector on which the mover 100″ travels. A section 12 can have arbitrarygeometry, and a path of a mover 100″ on any given section 12 couldfollow any 3 dimensional path (and not simply a linear or curved path).

By way of example, a track 10′ could have a rear side 191 elevated, sothat the track 10′ is at a 45 degree angle to level from a front side192 to the rear side 191. The amount of gravity compensation required asthe mover 100″ travels around the curve section 12 c′ (as shown) couldvary from zero acceleration at the start of the curve section 12 c′ tofunction which could be defined by sqrt(2)*g at the end of the curvesection 12 c′ (i.e., apex of the curve). Accordingly, a stored 3dimensional path of a mover 100″, along with a measured 3 dimensionalgravity vector 188 determined from a sensor 212 in the section 12, canbe used to calculate an appropriate gravity compensation value for eachlocation on the section.

Certain terminology is used herein for purposes of reference only, andthus is not intended to be limiting. For example, terms such as “upper,”“lower,” “above,” and “below” refer to directions in the drawings towhich reference is made. Terms such as “front,” “back,” “rear,”“bottom,” “side,” “left” and “right” describe the orientation ofportions of the component within a consistent but arbitrary frame ofreference which is made clear by reference to the text and theassociated drawings describing the component under discussion. Suchterminology may include the words specifically mentioned above,derivatives thereof, and words of similar import. Similarly, the terms“first,” “second” and other such numerical terms referring to structuresdo not imply a sequence or order unless clearly indicated by thecontext.

When introducing elements or features of the present disclosure and theexemplary embodiments, the articles “a,” “an,” “the” and “said” areintended to mean that there are one or more of such elements orfeatures. The terms “comprising,” “including” and “having” are intendedto be inclusive and mean that there may be additional elements orfeatures other than those specifically noted. It is further to beunderstood that the method steps, processes, and operations describedherein are not to be construed as necessarily requiring theirperformance in the particular order discussed or illustrated, unlessspecifically identified as an order of performance. It is also to beunderstood that additional or alternative steps may be employed.

It is specifically intended that the present invention not be limited tothe embodiments and illustrations contained herein and the claims shouldbe understood to include modified forms of those embodiments includingportions of the embodiments and combinations of elements of differentembodiments as coming within the scope of the following claims. All ofthe publications described herein including patents and non-patentpublications are hereby incorporated herein by reference in theirentireties.

What is claimed is:
 1. A system for propelling a mover, comprising: atrack segment defining a path along which a mover travels, the tracksegment comprising a drive coil for propelling a mover and a sensor fordetecting an orientation of the track segment; and a controller incommunication with the track segment, the controller executing a programstored in a non-transient medium to control power to the drive coil forpropelling the mover along the track segment with a force for achievinga motion profile, wherein the force is compensated by the orientation ofthe track segment as detected by the sensor.
 2. The system of claim 1,wherein the sensor comprises a multi-axis accelerometer arranged in thetrack segment.
 3. The system of claim 2, wherein the multi-axisaccelerometer is an electro mechanical system (MEMS) digitalaccelerometer configured to detect x, y and z components ofacceleration.
 4. The system of claim 3, wherein the track segmentfurther comprises a Printed Circuit Board (PCB), wherein the digitalaccelerometer is surface mounted to the PCB.
 5. The system of claim 1,wherein the orientation of the track segment comprises an angle of thetrack segment relative to a reference orientation.
 6. The system ofclaim 5, wherein the reference orientation of the track segment isdefined by an angle of 0° with respect to a level surface, and whereinthe angle of the track segment is a non-zero angle relative to thereference orientation.
 7. The system of claim 1, wherein the force iscompensated by compensating for gravity associated with the tracksegment.
 8. The system of claim 1, wherein the force comprises: adesired force for propelling the mover along the track segment whenarranged in a reference orientation; and a compensated force comprisingan acceleration compensating for the orientation of the track segmentdiffering from the reference orientation.
 9. The system of claim 1,wherein the track segment is arranged as a ramp.
 10. The system of claim1, further comprising the controller executing to determine theorientation of the track segment from the sensor to produce a result andcompare the result to a parameter for the track segment stored in a datastructure.
 11. The system of claim 1, further comprising the controllerexecuting to determine the orientation of the track segment from thesensor at first and second times to produce first and second results,respectively, and compare the first and second results to one another todetermine an error.
 12. The system of claim 11, further comprising thecontroller executing determine the orientation of the track segment atthe first and second times when a mover is moving along the tracksegment.
 13. The system of claim 12, further comprising the controllerexecuting to indicate an error caused by a faulty mover when theorientation of the track segment at the first and second times differfrom one another.
 14. A method for propelling a mover, comprising:providing a track segment defining a path along which a mover travels,the track segment comprising a drive coil for propelling a mover and asensor for detecting an orientation of the track segment; determining aforce for achieving a motion profile; compensating the force by theorientation of the track segment; and controlling power to the drivecoil for propelling a mover along the track segment by the compensatedforce.
 15. The method of claim 14, further comprising compensating theforce by compensating for gravity associated with the track segment. 16.The method of claim 14, further comprising arranging the track segmentas a ramp.
 17. The method of claim 14, further comprising determiningthe orientation of the track segment to produce a result and comparingthe result to a parameter for the track segment stored in a datastructure.
 18. The method of claim 17, further comprising determiningthe orientation of the track segment from the sensor at first and secondtimes to produce first and second results, respectively, and comparingthe first and second results to one another to determine an error. 19.The method of claim 18, further comprising determining the orientationof the track segment at the first and second times when a mover ismoving along the track segment.
 20. The method of claim 19, furthercomprising indicating an error caused by a faulty mover when theorientation of the track segment at the first and second times differfrom one another.